MW-Scale PEM-Based Electrolyzersfor RES Applications

Monjid Hamdan, Giner ELX (PI) Kevin Harrison, NREL Poster Session - April 30, 2019

DOE Hydrogen and Fuel Cells Program 2019 Annual Merit Review and Peer Evaluation Meeting

Project ID #: h2007

This presentation does not contain any proprietary, confidential, or otherwise restricted information.

Overview

Timeline and Budget • Project start date: 3/1/18 • Project end date: 1/16/20 • Total project budget: $300k

– Total recipient share: $30k – Total shared resources: $240k – Total federal share: $30k – Total funds spent*: $23k

Barriers • Cost of Hydrogen production

Partners • Giner ELX (CRD-18-742)

– PI: Monjid Hamdan • NREL ESIF Operations Team

– Danny Terlip, Owen Smith and Sam Jimenez and Kevin Harrison

* As of 3/1/19

NREL | 2

Relevance - Electrolyzer Stacks Regenerative Fuel Cell Systems

Target markets Intermittent Renewable Energy Source (RES)

integration Backup power for grid outages and load

shedding Increase RES ratio and ensure grid

stabilization AREVA’s energy storage platform ‘GREENERGY BOX’

in Corsica, France Utilizing Giner Low-Cost Electrolyzer Stack

Modular RFC systems with energy storage from 0.2 to 2 MWh

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Challenges & Needs MW Large Scale Projects

Wind-to-Hydrogen gaining momentum Microgrid Applications

Microgrid & hydrogen storage application on isolated island Centralized hydrogen production

adjacent wind farm

Primary source used to generate electricity: fossil fuels

Renewable energy sources provide 33% of total energy 25% from wind turbines 8% from solar panels

Target-100% energy from renewable power sources by 2020

Driver: Regulatory support

Storage Genset

Electrolyzer

Comp.

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Electrical Rectifier Controls w/

System & BOP Built to NEC/IEC standards

NFPA2/ATEX Compliant

Markets for Electrolyzer Systems Power to Mobility Power to Gas Power to Hydrogen

Giner 500kW-1MW HRS System -Mobile Refueling

Load Following for RES

Modular Systems 30,60,90,200 Nm3/hr

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Objectives & Goals Address critical aspects for the successful commercialization of Giner ELX’s

‘Allagash’ MW PEM-based electrolyzer platform Perform long-duration testing at Giner ELX and NREL to inform next-

generation MW-scale electrolyzer system development. Develop, assemble and test electrolyzer for use in Large-Scale Renewable

Energy applications Scale-up of PEM-based Electrolyzer Stack

Current 150kW platforms to 1-5 MW platforms Validate Performance at high current density (3A/cm2) at 30 bar

Stack decay rate, Fluoride release rates and H2 in O2

Cost reduction of Stack and improved manufacturability to reduce the cost of hydrogen production

6 220+ Nm3/hr

(MW Scale)

Approach

Three (3) primary tasks :

Task 1 (Giner ELX): Scale-up active area of the electrolyzer stack

290 cm² (150 kW platform) to 1,250 cm² (1 MW platform). Determine number of cells based on the power capabilities at NREL’s Energy Systems

Integration Facility (ESIF) test site Manufacture & Assemble multi-cell stack based on 1 MW stack platform

Task 2 (NREL): Modify electrolyzer testbed at NREL’s ESIF facility for large-scale electrolyzer stack testing Integrate, operate, and monitor stack testing over 5,000-hour period

Operate cyclically between a current density of 0 to 3 A/cm²

Task 3 (Giner ELX/NREL): Performance analysis

Evaluate efficiency, durability, and lifetime of the stack Analyze fluoride release rate to determine membrane degradation rates/stack lifetimes Monitor voltage performance / stability at current densities of 3 A/cm² Monitor cross-cell diffusion (%H2 in O2) Tear down: Determine impact on cell components and catalyst utilized in the MW stack

platform 7

Accomplishments Stack Build,

Integration into NREL ESIF Testbed

Giner ELX ¼ MW stack build assembled -Feb 19th, 2018 Stack Prechecks -Mar.-Jun., 2018 Stack delivered to NREL -July 21st, 2018 Installed into NREL testbed -Aug 23rd, 2018 Stack Design Specifications

Active Area: 1,250 cm² Build contains 29 Cells Operating Pressure: 40 bar Operating Temperature: 70C Operating mode: Differential Pressure Current (Nominal): 3,750 Amps ( 3 A/cm²) Includes support-base for ease of transport CE Compliant

Design Iteration: 6th Improvement in performance and/or lifetime achieved with each iteration Advancements implemented in other platforms to reduce cost/improve

lifetime

NREL-ESIF Modified Electrolyzer Test Bed to accommodate ‘Allagash’ MW-platform stack

New sensors, power cables, pressure regulator, pumps, etc.. Purchased & installed 2 new (4 total) 250 kW power supplies (AC/DC)

In current sharing mode, all supplies will provide the required current (3800A) to the Giner ELX stack

Test stand is now capable of a1MW stack Stack integrated into testbed and operational All cell voltages stable and within range

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Accomplishments - NREL Test Data

Data:

2 V/Cell ~3 A/cm² 65-70°C 30 bar H2

Cell 1 & 29 measured at Current Collector

Cell 29

~30 mV variance @ 3 A/cm² with exception of end cells

Stack operated with high water flow. These cells running cooler

Cell 1

300 hours of operation on 29-cell stack at various current and daily start/stop cycles %H2 in O2: <10% LFL (Water from H2 Separator drains into O2 Reservoir) Fluoride Release Rate measured: < 6 ppb (3 samples; control 5, 10, and 15 ppb)

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Accomplishments - Parallel Testing at Giner ELX

7-Cell Allagash Testing & Performance

~5,000 hrs. at 3A/cm², 15 bar ~5,000 hrs. at 3A/cm², 40 Bar (Ongoing)

Low Voltage Degradation rate <1 µV/hr over 10,000-hour period

10,000+ Total Operating Hours

(as of March 2019)

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Future Plans

Continue stack testing 5,000-hour period Operate stack cyclically between a current density of 0

to 3 A/cm² Continue performance evaluations (efficiency, durability,

lifetime) of the stack Analyze fluoride samples to determine membrane

degradation rates/stack lifetimes Monitor voltage performance / stability at current

densities of 3 A/cm² Determine impact on cell components and catalyst

utilized in the MW stack platform

Any proposed future work is subject to change based on funding levels 11

Cost Reduction, Volume Production

Key supply chain/production Solutions/Activities:

Cell Frames: Lead time reduced with purchase of injection mold Assembly & Sealing: Designed/Purchased Bolt Tensioner to reduce

labor and assembly time MEAs: Implemented R2R Catalyst for MW-Platform Capable of producing catalyst for 10-1MW stacks in one day Single Cell Architecture: Rapid production/Automation:

Latest Supported Traditional Single-piece Supported Membrane* Cell Membranes Enables Dry build Architecture*

Hard surface seal

*Developed under separate DOE project, Scale-up required for MW-Platforms

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1100

Nm

3 /hr E

lect

roly

zer S

tack

Emerging Designs for Future Applications

New Market Trends Require Larger Stacks

5 MW 12,500 Amp 25 kW/cell

1 MW+ > 5,000 Amp >10kW/cell

5MW Stack Platform Operating Pressure: 600 psig Active Area: 3,000+ cm² Current Density: 3,000+ mA/cm²

Development 2018 - 2020 Economics

Accelerates market opportunities

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Collaborations & Partnerships

• Giner ELX – PI: Monjid Hamdan – CRADA 18-742

• NREL – ESIF Operations Team – Danny Terlip, Owen Smith and

Sam Jimenez and Kevin Harrison

NREL Energy Systems Outdoor Test Facility

NREL Electrolyzer System

System Specifications • 20 – 70 bar differential pressure • 4000 Adc at 250 Vdc (1 MW DC) • H2 Purity: < 5 ppmv H2Ov

• 250 kW PEM stack → 5 kg H2 / hr • Compression w/ ~300 kg H2 storage

• 200, 400 and 900 bar NREL | 14

Summary

Objective • Develop, assemble and test electrolyzer for use in Large-Scale Renewable Energy applications

Accomplishments • Over 300 hours of operation at NREL on 29-cell stack

o < 2 V/cell at 3 A/cm2, 60 – 70C and 30 bar cathode pressure o Daily on/off cycles o Varying current to the stack o < 10% H2 in O2

o Water samples obtained and returned to Giner ELX for analysis o < 6 ppb Fluoride release rate

• Over 10,000 hours of operation at Giner ELX on 7-cell stack o < 1 uV/cell-hr over 10,000 hours of operation o 5000 hours at 15 bar cathode pressure o 5000 hours at 40 bar cathode pressure

Future Plans • Continue stack operations at NREL and Giner ELX monitoring for;

– Stack degradation rate, Fluoride release rate and H2 in O2

NREL | 15

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiencyand Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency

and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

Thank You

Publication Number

www.nrel.gov

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.